Making Props and Armour

So you want to make a prop? Does the character really need it? Does the character really need it? How will you be getting to the convention? Will it fit in the car/train/coach with no problems? Do you have to adjust it so it can? How will you be getting to the convention? Will it fit in the car/train/coach with no problems? Do you have to adjust it so it can? Check the guidelines for the con to see if you’re actually allowed props. Check the guidelines for the con to see if you’re actually allowed props. Then start thinking about how to make it! Then start thinking about how to make it!

So you’re going to make it now. Get good reference pictures. You can’t make something with guesswork, know what it actually looks like before you start buying materials. Get good reference pictures. You can’t make something with guesswork, know what it actually looks like before you start buying materials. STUDY the prop. Draw it, keep looking at it. Figure out how it goes together, UNDERSTAND IT. When you finally get around to making it all this prep work makes it a lot easier. STUDY the prop. Draw it, keep looking at it. Figure out how it goes together, UNDERSTAND IT. When you finally get around to making it all this prep work makes it a lot easier.

So, what you gonna make it out of? Craft foam Craft foam Plastazote foam Plastazote foam Other foam Other foam Wood Wood Plastic Plastic Cardboard Cardboard Fibre Glass Fibre Glass Mould making Mould making Other Other

Craft Foam

Pros- It’s cheap It’s cheap It won’t injure people It won’t injure people It’s light It’s light It’s easy to cut It’s easy to cutCons- It’s prone to cracking It’s prone to cracking You have to seal it well You have to seal it well

Plastazote Foam (my preferred method!)

Plastazote Pros- It’s cheap and comes in big sheets It’s cheap and comes in big sheets It won’t hurt people It won’t hurt people It can be crushed in transport and will re-shape itself It can be crushed in transport and will re-shape itself It’s easy to cut It’s easy to cut It can be heat formed It can be heat formedCons- It’s sealed with latex and roofing sealant so you need protective gear It’s sealed with latex and roofing sealant so you need protective gear

Other Foam

Pros It’s light It’s light You can sculpt it You can sculpt it It won’t hurt people It won’t hurt peopleCons It can be hard to get a hold of It can be hard to get a hold of It absorbs paint It absorbs paint It’s very hot to wear It’s very hot to wear

Wood

Wood Pros- You can buy it from a local store You can buy it from a local store It’s sturdy It’s sturdyCons- It’s difficult to cut (needs saws/electric tools) It’s difficult to cut (needs saws/electric tools) It’s banned at most conventions It’s banned at most conventions It’s hard to make it not look like wood It’s hard to make it not look like wood It’s brittle It’s brittle

Plastic

Plastic Pros It’s sturdy It’s sturdy It’s light It’s light It can be heat formed It can be heat formedCons It needs a lot of research and specialist tools It needs a lot of research and specialist tools It’s not cheap It’s not cheap It’s hard to paint It’s hard to paint It’s rigid so can injure others It’s rigid so can injure others

Cardboard

Cardboard Note: Corrugated card just sucks, I’m talking about using mount board. Pros- It’s light It’s light It’s cheap It’s cheap You can get it from most art stores You can get it from most art stores It takes paint well It takes paint well Good for small applications Good for small applicationsCons- It tears It tears It’s not waterproof It’s not waterproof Very hard to transport Very hard to transport

Fibre Glass There is no picture because I’ve never seen anyone pull this off well.

Fibre Glass Pros- It’s strong It’s strongCons- The fumes can kill you The fumes can kill you It’s expensive It’s expensive You can get shards of glass in your hands You can get shards of glass in your hands The insides are rough The insides are rough Requires A LOT of sanding to get smooth Requires A LOT of sanding to get smooth If you drop resin on the floor it ain’t coming off If you drop resin on the floor it ain’t coming off Generally leads to rage quitting. Generally leads to rage quitting.

Moulding

Moulding Pros- You get good detail You get good detail You can make more from the same mould You can make more from the same mouldCons- The detail is dependent on how good you are at sculpting The detail is dependent on how good you are at sculpting The materials can be costly to set up The materials can be costly to set up The insides of the final product can be not nice to human heads. The insides of the final product can be not nice to human heads.

Other

Other This is found objects like plumbing tubes, toy guns, random bits that look right Pros- Great thing for making guns Great thing for making guns Can be bought locally Can be bought locally Saves you from making a gun butt from scratch Saves you from making a gun butt from scratchCons- Can be hard to find things which are accurate Can be hard to find things which are accurate Can be hard to paint Can be hard to paint Can be heavy Can be heavy

So, you’ve got an idea of what you’ll make it with now? Test it. Buy a little bit of the material and see if it works for you. No point buying a crate of foam if you find out that you just can’t work with it! Test it. Buy a little bit of the material and see if it works for you. No point buying a crate of foam if you find out that you just can’t work with it! Make a mock up with paper/fabric/other before you cut the actual shape out of your material. It means you waste less. Make a mock up with paper/fabric/other before you cut the actual shape out of your material. It means you waste less.

Using Construction materials Card Card Craft foam Craft foam Plastazote Plastazote Thin plastics Thin plastics Thick plastics Thick plastics

Working with Card Use wood glue/PVA and slowly bend the object to shape. Use wood glue/PVA and slowly bend the object to shape. Coat with glue to waterproof it Coat with glue to waterproof it Don’t put strain on it as it will rip Don’t put strain on it as it will rip

Working with Craft foam Use a glue gun to glue into shape Use a glue gun to glue into shape Cut using a knife or scissors Cut using a knife or scissors You can heat mould it with a heat gun or by holding it over the hob You can heat mould it with a heat gun or by holding it over the hob Seal with PVA glue or paint will rub off Seal with PVA glue or paint will rub off

Working with Plastazote Use a glue gun or impact adheasive to glue into shape Use a glue gun or impact adheasive to glue into shape Cut using a knife or scissors Cut using a knife or scissors For weapons make supports with fibreglass rod For weapons make supports with fibreglass rod You can heat mould it with a heat gun or by holding it over the hob You can heat mould it with a heat gun or by holding it over the hob Seal with at least 3 layers of latex Seal with at least 3 layers of latex Paint with colours of your choice Paint with colours of your choice Final seal with isoflex Final seal with isoflex

Working with Thin Plastics Cut into shape with scissors or knife Cut into shape with scissors or knife Bend like card as it creases Bend like card as it creases Heat mould but keep in mind that it may curl Heat mould but keep in mind that it may curl Spray with primer so the paint stays on Spray with primer so the paint stays on Paint in colour of your choice Paint in colour of your choice Weather Weather Seal with clear acrylic spray Seal with clear acrylic spray

Working with Thick Plastics Cut into shape with knife or saw Cut into shape with knife or saw Sand rough edges Sand rough edges Will only bend if you heat mould it. Will only bend if you heat mould it. Spray with primer so the paint stays on Spray with primer so the paint stays on Paint in colour of your choice Paint in colour of your choice Weather Weather Seal with clear acrylic spray Seal with clear acrylic spray

Using Mould materials For Casting: Latex Latex Plaster Plaster Silicone Silicone For Moulding Hot glue Hot glue Polyurethane resin Polyurethane resin Latex Latex

Making a sculpt Use oil based clay as it doesn’t dry out Use oil based clay as it doesn’t dry out Build on a flat surface that it can be moved Build on a flat surface that it can be moved Using tools makes it much easier to get a smooth surface Using tools makes it much easier to get a smooth surface Think about how you will get the mould off Think about how you will get the mould off

Casting in Latex Use a soft paint brush to spread latex over the sculpt and avoid air bubbles Use a soft paint brush to spread latex over the sculpt and avoid air bubbles Apply several layers until the mould is thick Apply several layers until the mould is thick Make a support mould from plaster or plaster bandage. You can also use fibreglass… if you want to make it more difficult for yourself. Make a support mould from plaster or plaster bandage. You can also use fibreglass… if you want to make it more difficult for yourself.

Casting in Plaster Make a wall of clay or lego around the item you want to cast Make a wall of clay or lego around the item you want to cast Mix the plaster up adding plaster to water until it is thick Mix the plaster up adding plaster to water until it is thick Pour over the sculpt in a thin stream to get rid of bubbles Pour over the sculpt in a thin stream to get rid of bubbles Tap the base to vibrate it so the bubbles go to the top of the plaster Tap the base to vibrate it so the bubbles go to the top of the plaster Be prepared to pick your item out of the plaster once it’s set Be prepared to pick your item out of the plaster once it’s set

Casting in silicone This is about halfway between plaster and latex. This is about halfway between plaster and latex. You can paint it on or pour it on You can paint it on or pour it on It gets the best results, but is the most expensive It gets the best results, but is the most expensive You can buy it either in the cheaper form of window sealer or as a 2 part mix from mould suppliers You can buy it either in the cheaper form of window sealer or as a 2 part mix from mould suppliers

Moulding in Hot Glue Hot glue can be moulded in all of the mould options Hot glue can be moulded in all of the mould options Let your hot glue gun heat up until it’s easy to push the trigger Let your hot glue gun heat up until it’s easy to push the trigger Pour glue into the mould. Keep close to it so the glue hits the entire surface Pour glue into the mould. Keep close to it so the glue hits the entire surface Repeat until the entire inside of the mould is covered. Be aware that it can still be hot Repeat until the entire inside of the mould is covered. Be aware that it can still be hot If you have a really large flat area you can heat hot glue up in the oven in a glass jug If you have a really large flat area you can heat hot glue up in the oven in a glass jug

Moulding in Polyurethane resin Polyurethane resin! NOT POLYESTER. POLYESTER HATES YOU. Polyurethane resin! NOT POLYESTER. POLYESTER HATES YOU. Can be moulded in latex and silicone. Can be moulded in latex and silicone. Mix up the parts according to the instructions Mix up the parts according to the instructions Pour resin in a thin stream to avoid bubbles Pour resin in a thin stream to avoid bubbles Ensure you have good ventilation Ensure you have good ventilation The mould will get hot as the resin cures The mould will get hot as the resin cures Watch out for flies in the room Watch out for flies in the room

Moulding in Latex Can be moulded in plaster. Everything else distorts Can be moulded in plaster. Everything else distorts Pour a bit of latex in the mould and slush it about to cover the mould Pour a bit of latex in the mould and slush it about to cover the mould Repeat until you have the thickness you desire Repeat until you have the thickness you desire

Some things to consider when making props How will you get it there? How will you get it there? Work out the length of things by taking a picture of you compared to the character. If it comes to their knee, make it so it comes to yours. Work out the length of things by taking a picture of you compared to the character. If it comes to their knee, make it so it comes to yours.

Some things to consider when making armour The hardest bit with armour is figuring out how to make it stay on you. Look into how medieval armour actually works to get some ideas. The hardest bit with armour is figuring out how to make it stay on you. Look into how medieval armour actually works to get some ideas. Make it so you can go to the loo easily. Seriously. Make it so you can go to the loo easily. Seriously.

Now ask questions! (if we have enough time) Helpful links: – Great place for materials, especially plastazote – Great place to by materials, especially latex and casting materials if you’re trying something complicated – Absolute best place to buy random prop stuff from. Sounds obvious, but it’s true.